INSTALLATION MANUAL AND

OPERATING INSTRUCTIONS
MD41-( ) Series GPS ANNUNCIATION CONTROL UNIT
FOR GARMIN GPS 155/165

MFG. P/N: MD41-428 28VDC GARMIN P/N: 013-00029-00 Horizontal Mount

MFG. P/N: MD41-424 14VDC GARMIN P/N: 013-00029-01 Horizontal Mount
MFG. P/N: MD41-438 28VDC GARMIN P/N: 013-00029-05 Vert. Mount (shown on page 13)
MFG. P/N: MD41-434 14VDC GARMIN P/N: 013-00029-06 Vert. Mount (shown on page 13)

MID-CONTINENT INST. CO., INC MANUAL NUMBER 7015555

9400 E. 34th Street N., Wichita, KS 67226 USA REV. 5 Jan. 09, 1997
Phone 316-630-0101 • Fax 316-630-0723
MANUAL REVISION AND HISTORY

MANUAL: MD41-424, -434, -428, -438

REVISION: JUNE 14, 1995 REV. 1
MANUAL NUMBER: 7015555

Remove programming wakeup requirements shown on installation drawings.

REVISION: AUGUST 31, 1995 REV. 2

Add MD41-434, -438 vertical mount versions.

REVISION: NOVEMBER 6, 1995 REV. 3

Add MD41-428(5V)/438(5V) These part numbers have 5 volt push-button lighting.

REVISION: JANUARY 24, 1996 REV. 4

Added GPS annunciation interlock.

REVISION: JANUARY 09, 1997 REV. 5

Revised DO160C section 4.0 environmental test data. Test D1 is now F2

REV. 5 Jan. 09, 1997 2

 TABLE OF CONTENTS

SECTION 1 GENERAL DESCRIPTION

1.1 INTRODUCTION
1.2 SPECIFICATIONS, TECHNICAL
1.2.1 PHYSICAL CHARACTERISTICS
1.2.2 ENVIRONMENTAL CHARACTERISTICS
1.2.3 SPECIFICATIONS, ELECTRICAL
1.2.4 FRONT PANEL CONTROLS AND ANNUNCIATIONS
1.2.4.1 CONTROLS
1.2.4.2 ANNUNCIATIONS
1.2.5 INTERFACE
1.2.6 EQUIPMENT LIMITATIONS
1.2.7 MAJOR COMPONENTS

SECTION 2 INSTALLATION CONSIDERATIONS

2.1 COOLING
2.2 EQUIPMENT LOCATION
2.3 ADDITIONAL ANNUNCIATIONS
2.4 ADDITIONAL RELAYS
2.5 ROUTING OF CABLES

SECTION 3 INSTALLATION PROCEDURE

3.1 GENERAL INFORMATION
3.2 UNPACKING AND INSPECTING
3.3 MOUNTING THE MD41-( )
3.4 INSTALLATION LIMITATIONS

SECTION 4 POST INSTALLATION CHECKOUT

4.1 PRE-INSTALLATION TEST
4.2 OPERATING INSTRUCTIONS

FIGURE N0. LIST OF ILLUSTRATIONS

3.1 SCHEMATIC PINOUT, 25 PIN DSUB
3.2 SCHEMATIC PINOUT, 50 PIN DSUB
3.3 CUTOUT DIMENSION FOR PANEL MOUNTING
3.4 OUTLINE DRAWING
3.5 WIRING DIAGRAM, MD41-424/434 (14V)
3.6 WIRING DIAGRAM, MD41-428/438/428(5V)/438(5V) (28V)

APPENDIX
ENVIRONMENTAL QUALIFICATION FORM

REV. 5 Jan. 09, 1997 3

 SECTION 1 GENERAL DESCRIPTION

1.1 INTRODUCTION

The MD41-( ) is a self -contained GPS Annunciation and Control unit. It combines all the
necessary functions required for switching HSI/CDI data inputs between a conventional
VOR receiver and the Garmin GPS 155/165 approach-certified GPS receiver. In addition,
the MD41-( ) contains several GPS status annunciations used to indicate modes selected by
the front panel switches and various inputs from the GPS receiver.

A special ILS override feature has been incorporated to cause the MD41-( ) to
automatically switch to the NAV (VOR) mode when the VOR receiver is tuned to an ILS
frequency. Other features include dual, 16,000 hour lamps used for all annunciations,
internally lighted selection switches, automatic photocell dimming, and built-in
annunciation self test. A external annunciation dimming adjustment is provided for
balancing low level light conditions.

A 16 pole relay assembly is included within the MD41-( ) to simplify installation of the
switching between NAV (VOR), GPS and the associated HSI/CDI. All relays have gold
plated contacts and are nitrogen filled for high reliability.

Two versions are available that will allow the lighted selection buttons to operate from a
5 volt instrument dimming bus. These part numbers are as follows: MD41-428(5V) and
MD41-438(5V).

A MD156 adapter plate is available for front mount installations. Also a MD155 punch is
available for instrument hole cutout.

1.2 SPECIFICATIONS, TECHNICAL

1.2.1 PHYSICAL CHARACTERISTICS

Mounting: Panel
Width: 3.50 Inches
Height: 1.350 Inches
Depth: 4.625 Inches
Weight: 0.75 lbs.

1.2.2 ENVIRONMENTAL CHARACTERISTICS

TSO Compliance: TSO C129

Applicable Documents: RTCA DO-160C, DO-208
Operating Temperature Range: -55°C to +70°C
Humidity: 95% Non-Condensing

REV. 5 Jan. 09, 1997 4

 Altitude Range: 0 to 55,000 ft.
Vibration: Cat. M and N
Operational Shock: Rigid Mounting, 6 G Operational
15 G Crash Safety.

1.2.3 SPECIFICATIONS, ELECTRICAL

Design All Solid State

MD41-424/434 (14VDC) 0.65 Amps
MD41-428/438 (28VDC) 0.40 Amps
MD41-428(5V)/438(5V) (28VDC) 0.40 Amps
Relay contact current rating: 2 Amps DC
Available relay poles (spdt) 16

1.2.4 FRONT PANEL CONTROLS AND ANNUNCIATIONS

1.2.4.1 CONTROLS

NAV/GPS Alternate action switch, when pressed, will select

NAV (VOR) or GPS presentation on HSI/CDI.

GPS/APR Alternate action switch, when pressed, will arm GPS

Approach Mode.

GPS/SEQ Alternate action switch, when pressed, will select between

AUTO and HOLD modes.

LAMP TEST Momentary switch for testing annunciation lamps.

Note: Screwdriver adjustable control located on right side
of case sets annunciation low dimming level.

1.2.4.2 ANNUNCIATIONS

NAV NAV (VOR) information presented on the HSI or CDI.

GPS GPS information presented on the HSI or CDI.
ARM GPS is armed for automatic transition to approach mode.
ACTV GPS is actively engaged in the approach mode.
HOLD This will activate the course selector and also disable
the automatic GPS waypoint sequencing.
AUTO This will disable the course selector input to the GPS
and will enable automatic GPS waypoint sequencing.
MSG GPS message alert, from GPS receiver.
WPT GPS waypoint alert, from GPS receiver.

REV. 5 Jan. 09, 1997 5

1.2.5 INTERFACE (cont.)

GPS Approach Select Provides a logic low to the GPS receiver

(ARM) J1 Pin 24 when approach arm is selected.

GPS Sequence Select Provides a logic low to the GPS receiver

J1 Pin 9 when HOLD is selected.

GPS APR ACTV Receives a logic low from the GPS receiver
J1 Pin 8 when a transition is made from arm to active.

ILS Override Receives a logic low from the NAV (VOR)

JI Pin 14 receiver when tuned to an ILS frequency.
This will force the MD41-( ) into NAV mode
regardless of the NAV/GPS selection. This
connection is optional.

GPS Annunciation A logic low will cause the appropriate

annunciation to illuminate. GPS receiver must
be able to accept 80ma.

REV. 5 Jan. 09, 1997 6

1.2.6 EQUIPMENT LIMITATIONS

The MD41-( ) series control units contain specific dash numbers to be used with various GPS
receivers. The installer must match the correct controller part number with the GPS receiver
being installed.

The conditions and tests required for TSO approval of this article are minimum
performance standards. It is the responsibility of those desiring to install this article either
on or within a specific type or class of aircraft to determine that the aircraft installation
conditions are within the TSO standards. The article may be installed only if further
evaluation by the applicant documents an acceptable installation and is approved by the
Administrator.

The MD41-424/428/434/438/428(5V)/438(5V) is TSO’D and certified for use with the

Garmin GPS 155/165 systems. Any attempts to install the
MD41-424/428/434/438/428(5V)/438(5V) in a installation other than the Garmin GPS
155/165 is prohibited. This will void the TSO.

NOTE: Anytime the MD41-( ) is disconnected or removed from the aircraft, the HSI/CDI
will be inoperative in both NAV (VOR) and GPS.

1.2.7 MAJOR COMPONENTS

The system is comprised of one major component, the MD41-( ) GPS Annunciation Control
Unit.

REV. 5 Jan. 09, 1997 7

 SECTION 2 INSTALLATION CONSIDERATIONS

2.1 COOLING

No direct cooling is required. As with any electronic equipment, overall reliability may be
increased if the MD41-( ) is not located near any high heat source or crowded next to other
equipment. Means of providing a gentle air flow will be a plus.

2.2 EQUIPMENT LOCATION

The MD41-( ) must be mounted as close to the pilot’s field of view as possible. The preferable
location is near the HSI/CDI that will be displaying the GPS information. The unit depth, with
connector attached, must also be taken into consideration. A MD156 adapter plate is available
for front mounting.

2.3 ADDITIONAL ANNUNCIATIONS

Depending upon the installation and approving agency, you may be required to provided
additional NAV Source Select external enunciators near the HSI/CDI. Spare relay contacts
on the MD41-( ) J2 connector may be used for this purpose.

2.4 ADDITIONAL RELAYS

The MD41-( ) contains 16 relay poles. Some installations may require more than 16 poles due
to data lines, superflags etc. If this should occur, you may use one spare relay pole to switch
additional relays. In cases where it may be more desirable to have all the relay switching done
at a remote location, (i.e.: remote mounted equipment) one relay pole on the MD41-( ) may be
used for switching this bank of relays. Please note that the maximum relay contact rating for
the MD41-( ) is 2 amps DC.

2.5 ROUTING OF CABLES

Care must be taken not to bundle the MD41-( ) logic and low level signal lines with any high
energy sources. Examples of these sources include 400 HZ AC, Comm, DME, HF and
transponder transmitter coax. Always use shielded wire when shown on the installation print.
Avoid sharp bends in cabling and routing near aircraft control cables.

REV. 5 Jan. 09, 1997 8

 SECTION 3 INSTALLATION PROCEDURES

3.1 GENERAL INFORMATION

This section contains interconnect diagrams, mounting dimensions and other information
pertaining to the installation of the MD41-( ). After installation of cabling and before
installation of the equipment, ensure that power is applied only to the pins specified in the
interconnect diagram.

3.2 UNPACKING AND INSPECTING EQUIPMENT

When unpacking equipment, make a visual inspection for evidence of damage incurred during
shipment. The following parts should be included:

1. MD41-424 (14V) or MD41-428 (28V) Horiz. Mount

MD41-434 (14V) or MD41-438 (28V) Vert. Mount
MD41-428(5V) (28volt) 5 volt button lighting Horiz. Mount
MD41-438(5V) (28volt) 5 volt button lighting Vert. Mount
2. J1 Connector Kit (25 pin). MCI PN 7014517
3. J2 Connector Kit (50 pin). MCI PN 7014509
4. Installation Manual. MCI PN 7015555
5. 4-40 x 1.0” Mounting Screws, 4ea MCI PN 7016165

3.3 MOUNTING THE MD41-( )

Plan a location in the aircraft for the MD41-( ) to be mounted as close to the pilot’s field of
`view as possible. The preferable location is near the HSI/CDI that will be displaying the GPS
information. Avoid mounting close to heater vents or other high heat sources. Allow a
clearance of at least 3 inches from back of unit for plug removal.

The indicator is secured in place behind the panel since it is designed for rear mount only.
Make a panel cutout as shown in Figure 3-3. Secure the indicator in place with four 4-40 x 3/8
to 1.0” flat head phillips screws. A MD156 adapter plate is available for front mount
installations. Also a MD155 punch is available for hole cutout.

3.4 INSTALLATION LIMITATIONS

Wire the aircraft harness according to figure 3-5 or 3-6. Use at least 24 AWG wire for all
connections. You MUST use shielded wire where shown. Avoid sharp bends and routing
cable near high energy sources. Care must be taken to tie the harness away from aircraft
controls and cables. Normal installation techniques should be applied.

REV. 5 Jan. 09, 1997 9

 REAR VIEW OF J1 (bottom) CONNECTOR

J1
PIN NO.

1 ----------------------------- SPARE
2 ----------------------------- SPARE
3 ----------------------------- SPARE
4 ----------------------------- SPARE
5 ----------------------------- SPARE
6 ----------------------------- SPARE
7 ----------------------------- SPARE
8 ----------------------------- GPS APR ACTV ANNUNCIATION
9 ----------------------------- GPS SEQ HOLD (logic low to GPS)
10 --------------------------- MSG ANNUNCIATION
11 --------------------------- WPT ANNUNCIATION
12 --------------------------- 14 VDC UNIT PWR -424/434 ONLY
13 --------------------------- 28 VDC UNIT PWR -428/438/428(5V)/438(5V) ONLY
14 --------------------------- ILS FROM NAV(VOR) RECEIVER (for ILS override)(optional)
15 --------------------------- SPARE
16 --------------------------- SPARE
17 --------------------------- SPARE
18 --------------------------- SPARE
19 --------------------------- SPARE
20 --------------------------- DIM LOW (to lighting bus)(for push-button dimming)
21 --------------------------- DIM HIGH (to lighting bus)(for push-button dimming)
22 --------------------------- SPARE
23 --------------------------- TO NAV CIRCUIT BREAKER (for fault monitoring)
24 --------------------------- GPS ARM SELECT (logic low to GPS)
25 --------------------------- POWER GROUND

FIGURE 3-1 SCHEMATIC PINOUT, 25 PIN DSUB

REV. 5 Jan. 09, 1997 10

 Note 1: All relays shown in NAV position.
FIGURE 3-2 SCHEMATIC PINOUT, 50 PIN DSUB

REV. 5 Jan. 09, 1997 11

 MD156 Front Mounting Plate. Optional, must be ordered from Mid- Continent Inst.

ACTUAL SIZE
Note 1: Use four 4-40 X 3/8 to 1.0” Flat Head Phillips Screws for Mounting,
MCI PN 7016165 (supplied). MD155 punch is available for hole cutout.
FIGURE 3-3 CUTOUT DIMENSIONS FOR PANEL MOUNTING

REV. 5 Jan. 09, 1997 12

 FIGURE 3-4 OUTLINE DRAWING

REV. 5 Jan. 09, 1997 13

 FIGURE 3-5 WIRING DIAGRAM, MD41-424/434 GPS 155/165 (14V)

REV. 5 Jan. 09, 1997 14

 WIRING DIAGRAM, MD41-428/438/428(5V)/438(5V) GPS 155/165 (28V)

REV. 5 Jan. 09, 1997 15

 SECTION 4 POST INSTALLATION CHECKOUT

4.1 PRE INSTALLATION TESTS

With the MD41-( ) disconnected, turn on the avionics master switch and verify that aircraft
power is on pin 12 for 14VDC systems and pin 13 for 28VDC systems. Using an ohm meter,
verify pin 25 is aircraft ground.

4.2 OPERATING INSTRUCTIONS

Turn off the avionics master switch and connect the mating connector to the MD41-( ). Turn
on the avionics master switch and the MD41-( ) should come on with the following
annunciation’s.

1. NAV or GPS
2. HOLD or AUTO
3. MSG and/or WPT may be flashing depending on the status of the GPS
receiver.

Press the lamp test button, all annunciation’s should light. Continue pressing the lamp test
button and cover the photocell window located on the left side of the front panel. All
annunciation’s should dim.

Annunciation brightness at the minimum dimming level may be adjusted by rotation of the
dimmer control located on the right side of the MD41-( ) case. CW rotation lowers the
dimming level.

Select NAV using the NAV/GPS button. The presentation on the HSI/CDI will now be
information from the NAV receiver. Using a VOR test generator or equivalent VOR signal,
verify that the presentation and operation of the HSI/CDI is correct. This will include course
resolver, left-right meter, to-from meter and nav warn flag. Now select GPS on the MD41-( )
and tune the VOR receiver to an ILS frequency. The MD41-( ) will be forced to NAV mode
and ILS information will be displayed on the HSI/CDI. NOTE, this feature will not work if
“ILS Energize” was not connected at the time of installation.

Next, verify that HOLD and AUTO annunciations will cycle alternately when pressing the
GPS/SEQ button two times. Press the GPS/APR button and the ARM annunciation will
illuminate. ARM can be canceled by pressing the GPS/APR button a second time, or by
ACTV input from the GPS receiver. Please refer to section 4.0 of the Garmin installation
manual for the remaining system tests.

No periodic maintenance or calibration is necessary for continued airworthiness of the

MD41-( ).

REV. 5 Jan. 09, 1997 16

 ENVIRONMENTAL QUALIFICATION FORM

RTCA / DO160C

NOMENCLATURE: MD41-( ) GPS ANNUNCIATION CONTROL UNIT

MODEL NO: MD41-( ) TSO NO: C129

CLASS A1

MANUFACTURER TEST SPECIFICATION: MPS 7015613

MANUFACTURER: MID-CONTINENT INSTRUMENT CO., INC.

9400 E. 34th Street N.
WICHITA, KS 67226
PHONE (316)-630-0101 • FAX: (316)-630-0101

Conditions Section Description of Conducted Tests

Temperature and Altitude 4.0 Equipment tested to Categories A1 & F2 except as noted
Low Temperature 4.5.1
High Temperature 4.5.2 & 4.5.3
In-Flight Loss of Cooling 4.5.4 Cooling air not required
Altitude 4.6.1
Decompression 4.6.2
Overpressure 4.6.3 Not Tested

Temperature Variation 5.0 Equipment tested to Category C

Humidity 6.0 Equipment tested to Category A

Shock 7.0 Equipment tested per DO-160C

Operational 7.2 Par. 7.2.1
Crash Safety 7.3

Vibration 8.0 Equipment tested without shockmounts to Categories M

and N (Table 8-1)

Explosion 9.0 Equipment identified as Category X, no test required

Waterproofness 10.0 Equipment identified as Category X , no test required

Fluids Susceptibility 11.0 Equipment identified as Category X, no test required

REV. 5 Jan. 09, 1997 17

 Environmental Qualification (cont.)

Conditions Section Description of Conducted Tests

Sand and Dust 12.0 Equipment identified as Category X, no test required

Fungus 13.0 Equipment identified as Category X, no test required

Salt Spray 14.0 Equipment identified as Category X, no test required

Magnetic Effect 15.0 Equipment tested to Class Z

Power Input 16.0 Equipment tested to Category B

Voltage Spike 17.0 Equipment tested to Category A

Audio Frequency 18.0 Equipment tested to Category B

Susceptibility
Induced Signal Susceptibility 19.0 Equipment tested to Category A

Radio Frequency 20.0 Equipment tested to Category T

Susceptibility
Radio Frequency Emissions 21.0 Equipment tested to Category Z

Lightning Induced Transient 22.0 Equipment identified as Category X, no tests required

Susceptibility

Lightning Direct Effects 23.0 Equipment identified as Category X, no tests required

Icing 24.0 Equipment identified as Category X, no test required

REV. 5 Jan. 09, 1997 18